Emitter electrode having a strip shape

ABSTRACT

A strip-shaped emitter electrode including at least one emission edge extending along the length of such emitter electrode. When the strip-shaped emitter electrode is coupled to a voltage supply, current or an electrical charge at the emission edge ionizes the air and generates corona discharge, resulting in ion production. Erosion occurs at the emission edge such that the lifespan of the strip emitter electrode is dependent, at least in part, on the width of the strip emitter electrode.

PRIORITY CLAIM

This application claims priority to, and is a continuation in part of, pending U.S. patent application Ser. No. 11/694,281, filed Mar. 30, 2007, which is a continuation in part of pending U.S. patent application Ser. No. 11/007,734, filed Dec. 8, 2004, which is a continuation of U.S. patent application Ser. No. 10/717,420, filed Nov. 19, 2003, now abandoned, which claimed priority to U.S. Provisional Patent Application No. 60/500,437, filed Sep. 4, 2003, now expired, all of which are fully incorporated herein by reference.

CROSS REFERENCE TO RELATED APPLICATIONS

This application relates to the following commonly-owned co-pending patent applications: U.S. Patent Appln. No. Filed Docket No. 90/007,276 Oct. 29, 2004 112440-068 11/041,926 Jan. 21, 2005 112440-072 11/091,243 Mar. 28, 2005 112440-352 11/062,057 Feb. 18, 2005 112440-441 11/071,779 Mar. 3, 2005 112440-702 10/994,869 Nov. 22, 2004 112440-703 11/007,556 Dec. 8, 2004 112440-709 10/074,209 Feb. 12, 2002 112440-727 10/685,182 Oct. 14, 2003 112440-743 10/944,016 Sep. 17, 2004 112440-744 10/795,934 Mar. 8, 2004 112440-761 10/435,289 May 9, 2003 112440-762 11/064,797 Feb. 24, 2005 112440-769 11/003,671 Dec. 3, 2004 112440-774 11/003,035 Dec. 3, 2004 112440-775 11/007,395 Dec. 8, 2004 112440-776 10/876,495 Jun. 25, 2004 112440-783 10/809,923 Mar. 25, 2004 112440-784 11/004,397 Dec. 3, 2004 112440-798 10/895,799 Jul. 21, 2004 112440-799 10/642,927 Aug. 18, 2003 112440-803 11/823,346 Apr. 12, 2004 112440-804 10/662,591 Sep. 15, 2003 112440-805 11/061,967 Feb. 18, 2005 112440-806 11/150,046 Jun. 10, 2005 112440-848 11/188,448 Jul. 25, 2005 112440-877 11/188,478 Jul. 25, 2005 112440-878 11/293,538 Dec. 2, 2005 112440-932 11/457,396 Jul. 13, 2006 112440-966 11/464,139 Aug. 11, 2006 112440-969 11/694,281 Mar. 30, 2007 112440-1010

INCORPORATION BY REFERENCE

The contents of the following patent applications and issued patents are fully incorporated herein by reference: U.S. Patent Appln. No. Filed U.S. Pat. No. Docket No. 90/007,276 Oct. 29, 2004 112440-68 09/419,720 Oct. 14, 1999 6,504,308 112440-68US2 11/041,926 Jan. 21, 2005 112440-72 09/231,917 Jan. 14, 1999 6,125,636 112440-344 11/091,243 Mar. 28, 2005 112440-352 10/978,891 Nov. 1, 2004 112440-355 11/087,969 Mar. 23, 2005 7,056,370 112440-361 09/197,131 Nov. 20, 1998 6,585,935 112440-381 08/924,580 Sep. 5, 1997 5,802,865 112440-397 09/148,843 Sep. 4, 1998 6,189,327 112440-400 09/232,196 Jan. 14, 1999 6,163,098 112440-407 10/454,132 Jun. 4, 2003 6,827,088 112440-408 09/721,055 Nov. 22, 2000 6,640,049 112440-409 10/405,193 Apr. 1, 2003 112440-410 09/669,253 Sep. 25, 2000 6,632,407 112440-414 09/249,375 Feb. 12, 1999 6,312,507 112440-416 09/742,814 Dec. 19, 2000 6,672,315 112440-417 09/415,576 Oct. 8, 1999 6,182,671 112440-418 09/344,516 Jun. 25, 1999 6,152,146 112440-419 09/163,024 Sep. 29, 1998 5,975,090 112440-420 11/062,057 Feb. 18, 2005 112440-441 10/188,668 Jul. 2, 2002 6,588,434 112440-501 10/815,230 Mar. 30, 2004 6,953,556 112440-528 11/003,516 Dec. 3, 2004 112440-701 11/071,779 Mar. 3, 2005 112440-702 10/994,869 Nov. 22, 2004 112440-703 11/007,556 Dec. 8, 2004 112440-709 11/003,894 Dec. 3, 2004 112440-710 10/661,988 Sep. 12, 2003 7,097,695 112440-712 10/774,579 Feb. 9, 2004 7,077,890 112440-714 09/730,499 Dec. 5, 2000 6,713,026 112440-715 10/156,158 May 28, 2002 6,863,869 112440-716 09/186,471 Nov. 5, 1998 6,176,977 112440-717 11/003,752 Dec. 3, 2004 112440-721 10/835,743 Apr. 30, 2004 6,908,501 112440-722 10/791,561 Mar. 2, 2004 112440-723 10/658,721 Sep. 9, 2003 6,896,853 112440-724 11/006,344 Dec. 7, 2004 112440-726 10/074,209 Feb. 12, 2002 112440-727 10/023,460 Dec. 13, 2001 112440-728 10/379,966 Mar. 5, 2003 112440-742 10/685,182 Oct. 14, 2003 112440-743 10/944,016 Sep. 17, 2004 112440-744 10/074,096 Feb. 12, 2002 6,974,560 112440-749 10/074,347 Feb. 12, 2002 6,911,186 112440-750 10/795,934 Mar. 8, 2004 112440-761 10/435,289 May 9, 2003 112440-762 09/774,198 Jan. 29, 2001 6,544,485 112440-763 11/064,797 Feb. 24, 2005 112440-769 11/003,034 Dec. 3, 2004 112440-772 11/003,671 Dec. 3, 2004 112440-774 11/003,035 Dec. 3, 2004 112440-775 11/007,395 Dec. 8, 2004 112440-776 10/074,827 Feb. 12, 2002 112440-779 10/876,495 Jun. 25, 2004 112440-783 10/809,923 Mar. 25, 2004 112440-784 11/062,173 Feb. 18, 2005 112440-788 10/074,082 Feb. 12, 2002 6,958,134 112440-789 10/278,193 Oct. 21, 2002 6,749,667 112440-793 09/924,600 Aug. 8, 2001 6,709,484 112440-794 09/564,960 May 4, 2000 6,350,417 112440-795 10/806,293 Mar. 22, 2004 6,972,057 112440-796 11/004,397 Dec. 3, 2004 112440-798 10/895,799 Jul. 21, 2004 112440-799 10/625,401 Jul. 23, 2003 6,984,987 112440-802 10/642,927 Aug. 18, 2003 112440-803 11/823,346 Apr. 12, 2004 112440-804 10/662,591 Sep. 15, 2003 112440-805 11/061,967 Feb. 18, 2005 112440-806 11/150,046 Jun. 10, 2005 112440-848 11/188,448 Jul. 25, 2005 112440-877 11/188,478 Jul. 25, 2005 112440-878 60/777,943 Feb. 25, 2006 112440-897 11/293,538 Dec. 2, 2005 112440-932 11/338,974 Jan. 25, 2006 112440-941 10/794,526 Mar. 4, 2004 7,014,686 112440-949 10/267,006 Oct. 8, 2002 6,899,745 112440-949DIV 11/457,396 Jul. 13, 2006 112440-966 11/464,139 Aug. 11, 2006 112440-969 10/168,723 Jun. 21, 2002 6,897,617 112440-975 10/168,724 Jun. 21, 2002 6,603,268 112440-978

BACKGROUND

Existing wire emitter electrodes (referred to as “Prior Art Wire Emitter(s)”) ionize the air and generate corona discharge at levels proportionate to the current running through the electrode. Such electrodes are operatively coupled to a voltage supply which enables such current flow. The amount of ionized particles and corona discharge generated is a function of the emitter current. The higher the emitter current, the more air is ionized and the greater the corona discharge.

Ozone production can be a byproduct of corona discharge if certain conditions are present. This ionization process can cause oxygen molecules (O₂) to split in the air. The split molecules seek stability and attach themselves to other oxygen molecules (O₂), forming ozone (O₃). Inhaling excess amounts of ozone can be undesirable and even harmful depending upon the conditions present in a given environment. Ozone generation for a given Prior Art Wire Emitter length at normal room humidity, temperature and pressure can be a function of the material of the wire, the emitter current and the diameter of the wire. For a given emitter current and material, the smaller the diameter of the wire, the less ozone is produced. One disadvantage to small diameter wires is that they tend to wear down at a relatively high rate.

Accordingly, there is a need to overcome or otherwise reduce the disadvantages described above.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a perspective view of a Prior Art Wire Emitter.

FIG. 1B is a perspective view of one embodiment of a strip emitter electrode, as described below.

FIG. 1C is an enlarged, perspective view of one embodiment of a strip emitter electrode, as described below.

FIG. 2 is a graph indicating ozone production of an air treatment apparatus using one embodiment of a strip emitter electrode compared to a Prior Art Wire Emitter electrode used to generate the same emitter current.

FIG. 3 is a front perspective view of one embodiment of an air treatment apparatus which includes the strip emitter electrode described below.

DETAILED DESCRIPTION

FIG. 1A illustrates a perspective view of a Prior Art Wire Emitter. The use of a strip emitter electrode 10, as illustrated in FIGS. 1B and 1C, overcomes or reduces the problems related to Prior Art Wire Emitters by exhibiting a longer structural lifetime and generating desired levels of corona discharge associated with acceptable amounts of ozone.

Referring now to FIGS. 1B and 1C, in one embodiment, the strip emitter electrode 10 includes a rectangular body having a length 12, a width 14, a thickness 16, and emission edges 18 a and 18 b. Edges 18 a and 18 b are defined by the length 12 and the thickness 16, and edges 18 a and 18 b extend along the length 12 of the strip emitter electrode 10. When a current flows through the strip emitter electrode 10, corona current concentrates on at least one of edges 18 a and 18 b. Accordingly, any erosion of the strip emitter electrode 10 caused by corona current progresses from the respective edge 18 a or 18 b of the strip emitter electrode 10 inward along the width 14. This enables strip emitter electrode 10 to perform the ionic emission function for a relatively long period of time. The concentration of corona at at least one of edges 18 a and 18 b of the strip emitter electrode 10 results in ionization similar to that resulting from corona emitted from a thin wire within corresponding levels of ozone generation.

With continued reference to FIG. 1C, erosion may progress inward from edge 18 a. For example: after one period of operation, the edge 18 a deteriorates and recedes to line 20 a; after a longer period of operation, the edge 18 a deteriorates and recedes to line 20 b; and after an even longer period of time, the edge 18 a deteriorates and recedes to line 20 c. In on example, this process continues until the entire width 14 of the strip emitter electrode is depleted or disintegrated. The lifespan of the strip emitter electrode 10 is a function, in part, of the width 14 of the strip emitter electrode 10. All other variables being equal, in this example, the greater the width 14, the longer the lifespan of a strip emitter electrode 10. If edge 18 a of the strip emitter electrode 10 were the only edge eroding due to current concentration, the life of the strip emitter electrode 10 would terminate approximately when the erosion reaches edge 18 b. If both edges 18 a and 18 b are eroding due to current concentration, the life of the strip emitter electrode 10 would terminate approximately when the erosions lines extending inward from respective edges 18 a and 18 b converge.

Such a strip emitter electrode 10 may have any suitable rectangular geometry and have any suitable length 12, width 14 and thickness 16. For example, the width 14 of the strip emitter electrode 10 could extend from 0.1 mm upward. Additionally, the thickness 16 of the strip emitter electrode 10 could range from 0.01 mm to 0.15 mm. In one tested embodiment, the width 14 of the strip emitter electrode 10 is approximately 2.3 mm, and the thickness 16 of the strip emitter electrode 10 is approximately 0.02 mm. Additionally, the strip emitter electrode 10 may be composed of any suitable material. In one embodiment, the strip emitter electrode 10 is composed of molybdenum. In the illustrated and tested embodiment, the strip emitter electrode 10 has a flexible foil structure. It should be appreciated, however, that the strip emitter electrode 10 can have any suitable rigid or flexible structure, including, but not limited to: (a) a ribbon; (b) a foil; (c) a tape; (d) a belt or band; or (e) any other suitable relatively thin structure.

Referring now to Table 1 below, to demonstrate the relationship between Prior Art Wire Emitter diameter and ozone generation, consider a tungsten Prior Art Wire Emitter electrode between 0.1 and 0.12 mm in diameter. The following table illustrates the ozone production of such a Prior Art Wire Emitter electrode at a designated current as a function of the diameter of the wire. TABLE 1 Wire Diameter, mm O3, mg/hr 0.12 2.62 0.1 2.23 0.08 1.96

As illustrated in Table 1, ozone generation resulting from such Prior Art Wire Emitter decreases with wire diameter. However, as described above, smaller diameter wires may not have a sufficient lifespan for practical application, breaking and requiring replacement because corona current erodes the Prior Art Wire Emitters.

In one test, ozone generation of an air treatment apparatus including Prior Art Wire Emitter electrodes was measured as a function of current at designated currents. Then, ozone generation of the same air treatment apparatus including a plurality of the strip emitter electrodes 10 was measured at the same current. Then, the two sets of results where compared, as illustrated in Table 2 below. For this test, Prior Art Wire Emitters having a diameter of 0.12 mm were used. Molybdenum strip emitter electrodes, having a width of 2.3 mm and a thickness of 0.02 mm, were used. In this particular test, both the Prior Art Wire Emitters and such strip emitter electrodes 10 were operated in an air treatment apparatus which also includes collector and driver electrodes. In this test, the emitter electrodes and the collector electrodes were operatively coupled to a voltage generator. Table 2 below and FIG. 2 include relevant test data. TABLE 2 O3, mg/hr O3, mg/hr Strip Emitter Prior Art Wire Emitter I, μA Electrodes Electrodes 200 1.8 2.8 400 3.7 5.5 600 5.5 8

As illustrated in Table 2 and FIG. 2, operating at the same designated currents, the use of the strip emitter electrodes resulted in less ozone generation than the use of the Prior Art Wire Emitter electrodes.

Performance of the air treatment apparatus used in this test was also measured in terms of Clean Air Delivery Rate (“CADR”). CADR is the amount of clean air measured in cubic feet per minute that an air cleaner delivers to a room. The performance of the air treatment apparatus used in this particular test, independent of ozone generation differentiation, was substantially similar when using the strip emitter electrodes 10, as opposed to the Prior Art Wire Emitters. This is illustrated by the sample estimated CADR results of Table 3 below. The “High,” “Med,” “Low,” and “Quiet” designators in Table 3 refer to various operating modes of the air treatment apparatus from which these results were measured. While performing at similar CADR levels, the ozone generation using strip emitter electrodes 10 was significantly lower. TABLE 3 CADR (Prior Art Wire Emitter CADR Mode Electrode) (Strip Emitter Electrode) High 155.4 174.3 Medium 137.6 138.6 Low 124.3 135.2 Quiet 100.6 110.3

It should be appreciated that although the strip emitter electrode 10 described in this application was tested in an air treatment apparatus including a collector electrode in the foregoing example, the strip emitter electrode 10 may be incorporated into a variety of air treatment devices including, without limitation, various electrode configurations, pure ionizers (such as a strip emitter electrode which causes ions to flow toward any suitable grounded object), or any other suitable device. For example, the strip emitter electrode could be utilized in air treatment devices including at least one of: (a) emitter electrodes; (b) collector electrodes; (c) electrodes interstitially located between the collector electrodes (driver electrodes); and (d) additional suitable electrodes. An example of such a device is shown in FIG. 3, which illustrates an air treatment apparatus including an elongated housing which supports the internal components of the air treatment apparatus. In this illustration, the air treatment apparatus could include an electrode assembly with at least one of the strip emitter electrodes 10 illustrated in FIGS. 1B and 1C. Though the housing shown has an elongated shape, it should be understood that other shapes for the air treatment apparatus are suitable. In one embodiment, such air treatment apparatus includes a control panel for turning on and off the air treatment apparatus, or for changing operating settings (e.g., low, medium, high or quiet). In operation, the air treatment apparatus draws surrounding air into the apparatus through the front air inlet. The front air inlet can include a plurality of fins, slats or louvers that facilitate air flow into the apparatus. An electrode assembly in the air treatment apparatus cleans or removes particles from the air as air flows through the apparatus.

The apparatus can remove dust particles and other airborne particles from the air, including particles which cause odor, as well as particles present in smoke and other gases. Also, the apparatus can condition and treat the air by removing or altering chemicals present in the air. Furthermore, the apparatus can collect and kill airborne pathogens and micro-organisms through the effect of the electric field produced by the electrode assembly and cold plasma of corona discharge. Once cleaned or otherwise treated, the air exits the apparatus through the rear air outlet. Similar to the front air inlet, the rear air outlet can include a plurality of fins, slats or louvers that facilitate air flow out of the apparatus.

In one embodiment, the strip emitter electrode 10 includes a first end and a second end, the first and second end both held by a tensioning mechanism or holder which holds the strip emitter electrode tight in a linear configuration, eliminating or reducing slack.

In various embodiments, the strip emitter electrode may be either a permanent or replaceable component of an air treatment apparatus or any device. Alternatively, the strip emitter electrode may constitute a device in and of itself (i.e., a pure ionizer as described above), used with a voltage source. In such embodiment, the strip emitter electrode can be a replaceable item.

Additionally, the strip emitter electrode may be fabricated in a variety of ways and by a variety of devices. For example, the strip emitter electrode could be produced as a product of: (a) a laser cutting method; (b) mechanical cutting method; (c) any combination of these methods; or (d) any suitable fabrication method like, for example, rolling. Such methods could employ a variety of cutting devices, including: (i) lasers; (ii) mechanical cutters; (iii) any combination of these devices; or (iv) any suitable device.

It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. 

1. An electrode comprising: a rectangular body having a length, a width, a thickness, and a plurality of edges which extend along the length, the rectangular body being configured to be operatively coupled to a voltage source, the voltage source being operable to cause: (a) ionization; and (b) erosion of at least one of the edges, the erosion progressing toward the other edge.
 2. The electrode of claim 1, wherein the electrode has a flexible characteristic, a first end, and a second end, the first end and the second being configured to be held in place by at least one holder.
 3. The electrode of claim 1, wherein the electrode is fabricated using a cutting or rolling device selected from the group consisting of: (a) a laser; (b) a mechanical cutter; (c) any combination of a laser and a mechanical cutter; and (d) a roller.
 4. The electrode of claim 1, wherein the electrode is a component of an ionic air treatment apparatus.
 5. The electrode of claim 1, wherein the electrode is a component of an ionizer.
 6. The electrode of claim 1, wherein the electrode has a structure selected from the group consisting of: (a) a ribbon; (b) strip; (c) a foil; (d) a tape; (e) a belt; and (f) a band.
 7. The electrode of claim 6, wherein the electrode is flexible along the length. 